Systems and methods for monitoring and estimating service life of electrical fuses

ABSTRACT

A fuse monitoring system for monitoring a fuse is provided. The system includes a fuse monitoring assembly and a fuse monitoring computing device. The fuse monitoring assembly includes at least one sensor configured to measure fuse data associated with the fuse, the fuse data including operational data of the fuse and environmental data of an environment in which the fuse locates, the environmental data including shock and vibrations. The fuse monitoring assembly also includes at least one processor configured to transmit the fuse data to a remote computing device. The fuse monitoring computing device is positioned remotely from the fuse monitoring assembly, the fuse monitoring computing device including at least one processor in communication with at least one memory device. The fuse monitoring computing device is programmed to receive, from the fuse monitoring assembly, the fuse data, analyze the fuse data, and generate a fuse message based on the analysis.

BACKGROUND

The field of the disclosure relates generally to monitoring systems forelectrical power systems, and more particularly to systems, assemblies,and methods for monitoring of electrical circuit protection fuses.

Fuses are widely used as overcurrent protection devices to preventcostly damage to electrical circuits. Fuse terminals typically form anelectrical connection between an electrical power source or power supplyand an electrical component or a combination of components arranged inan electrical circuit. One or more fusible links or elements, or a fuseelement assembly, is connected between the fuse terminals, so that whenelectrical current flowing through the fuse exceeds a predeterminedlimit, the fusible elements melt and open one or more circuits throughthe fuse to prevent electrical component damage.

Fuse failure in electric-powered vehicles can either be a nuisance orresult in an emergency. Fuses in electric-powered vehicles are subjectedto temperature fluctuations, humidity, shock and vibration, potentiallycausing fuse fatigue and decreasing the service life of the fuse. Insome other known applications, electrical enclosures house electricalcomponents such as fuses inside. For example, in hazardous industrialenvironments such as mines, refineries and petroleum chemical plants,ignitable gas, vapors, dust or otherwise flammable substances arepresent in the ambient environment of the electrical enclosure, and theelectrical enclosures are subject to temperature fluctuations, humidity,potentially causing fuse fatigue and decreasing the service life of thefuse.

Known fuse monitoring systems are disadvantaged in some aspect to meetthe needs of challenging applications such as those described, theyremain disadvantaged and improvements are desired.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments are described with referenceto the following Figures, wherein like reference numerals refer to likeparts throughout the various drawings unless otherwise specified.

FIG. 1 is a schematic diagram of an exemplary fuse monitoring system.

FIG. 2 is a block diagram of an exemplary fuse monitoring assembly foruse with the fuse monitoring system shown in FIG. 1 .

FIG. 3 is a perspective view of an exemplary embodiment of the fusemonitoring assembly for use with the fuse monitoring system shown inFIG. 1 , wherein the fuse monitoring assembly is shown to be coupled toa fuse housing.

FIG. 4 is a partially exploded assembly view of the fuse monitoringassembly, one or more fuses, and the fuse housing.

FIG. 5 is an exploded view of a portion the fuse monitoring assemblyshown in FIG. 3 .

FIG. 6 is a cross-sectional view of the fuse monitoring assemblyconnected to the fuse housing shown in FIG. 3 along cross-sectional line6-6 shown in FIG. 3 .

FIG. 7 is a detailed view of the fuse monitoring assembly showing thecurrent sensor.

FIGS. 8A and 8B illustrate a plurality of views of an exemplary userinterface used to monitor a fuse with the system shown in FIG. 1 .

FIG. 9 is a top plan view of a high voltage power fuse that may be usedwith the fuse monitoring system shown in FIGS. 1 and 2 .

FIG. 10 is an exemplary flow chart of an exemplary process of monitoringa fuse.

FIG. 11 is an exemplary flow chart of an exemplary process of predictinga fuse service life.

FIG. 12 is a block diagram of an exemplary user computing device.

FIG. 13 is a block diagram of an exemplary server computing device.

DETAILED DESCRIPTION

Recent advancements in electric vehicle (EV) technologies, presentunique challenges for fuse manufacturers. Electric vehicle manufacturersare seeking fusible circuit protection for electrical power distributionsystems operating at voltages much higher than conventional electricalpower distribution systems for vehicles, while simultaneously seekingless costly fuses with effective monitoring functionality to facilitatedetection of impending failure conditions, for example, to meet electricvehicle specifications and demands.

Electrical power systems for conventional, internal combustionengine-powered vehicles operate at relatively low voltages, typically ator below about 48 VDC. Electrical power systems for electric-poweredvehicles, referred to herein as electric vehicles (EVs), however,operate at much higher voltages. The relatively high voltage systems(e.g., 200 VDC and above) of EVs generally enables the batteries tostore more energy from a power source and provide more energy to anelectric motor of the vehicle with lower losses (e.g., heat loss) thanconventional batteries storing energy at 12 volts or 24 volts used withinternal combustion engines, and more recent 48 volt power systems.

EV original equipment manufacturers (OEMs) employ circuit protectionfuses to protect electrical loads in all-battery electric vehicles(BEVs), hybrid electric vehicles (HEVs) and plug-in hybrid electricvehicles (PHEVs). Across each EV type, EV manufacturers seek to maximizethe mileage range of the EV per battery charge while reducing cost ofownership. Accomplishing these objectives turns on the energy storageand power delivery of the EV system, as well as the cost, size, volume,and mass of the vehicle components that are carried by the power system.Smaller, more affordable, and/or lighter vehicles will more effectivelymeet these demands than larger, more expensive, and heavier vehicles,and as such all EV components are now being scrutinized for potentialsize, weight, and cost savings.

Generally speaking, more complex electrical components with monitoringsystems tend to have higher associated material costs, higher finishedcomponent costs, occupy an undue amount of space, and introduce greatermass that directly reduces the vehicle mileage per single battery chargein EV power systems. Known high voltage circuit protection fusesincorporating aspects of performance and service life monitoring are,however, relatively complex, expensive, and relatively large.Historically, and for good reason, conventional circuit protection fuseshave also tended to increase in complexity, cost, and size to meet thedemands of high voltage power systems as opposed to lower voltagesystems. As such, existing fuses needed to protect high voltage EV powersystems tend to be much larger than the existing fuses needed to protectthe lower voltage power systems of conventional, internal combustionengine-powered vehicles. Smaller or more compact high voltage powerfuses incorporating performance and service life monitoring features aredesired to meet the needs of EV manufacturers, without sacrificingcircuit protection performance and reliability.

Electrical power systems for state of the art EVs may operate atvoltages as high as 450 VDC. The increased power system voltagedesirably delivers more power to the EV per battery charge. Operatingconditions of electrical fuses in such high voltage power systems aremuch more severe, however, than lower voltage systems. Specifically,specifications relating to electrical arcing conditions as the fuseopens can be particularly difficult to meet for higher voltage powersystems, especially when coupled with the industry preference forreduction in the size of electrical fuses.

Temperature cycling, caused by fluctuations in ambient temperature andcurrent cycling, imposed on power fuses by state of the art EVs alsotend to impose mechanical strain and wear that can lead to shortening ofthe fuse's expected service life and premature failure of a conventionalfuse element due to fuse element fatigue. Fuses used in EV applicationsare also exposed to environmental conditions that influence the expectedservice life and/or affect the functional performance of the fuse. Forexample, fuses used in an EV power system are exposed to the shock andvibration caused by movement of the EV during travel, potentiallyfurther contributing to fatigue and reduced service life of the fuse.Fuses are also exposed to fluctuations in ambient temperature andhumidity in an EV power system that may also contribute to fuse fatiguedecrease the service life of the fuse.

While known power systems incorporating fuse temperature and servicelife monitoring features are known, they are disadvantaged in someaspects for desirable use in high voltage circuitry in state of the artEV applications. In particular, known monitoring assemblies that accountfor environmental conditions of the fuse in addition to operationalparameters to determine fuse service life and/or assess fuse performanceare too large, too complicated, or prohibitively expensive or unreliablein certain aspects to meet the needs of EV power systems. Long felt butunresolved needs to meet the particular needs of EV power systems havetherefore not been completely resolved in the marketplace. Accordingly,with the goal of replacing fatigued fuses prior to failure while in viewof the expanding use of electric-powered vehicles and other powersystems presenting similar issues, compact, affordable, and reliablefuse monitoring systems and methods to detect and evaluate a pluralityof real-time parameters the collectively contribute to fuse fatigue toassess fuse performance and predict or estimate a remaining service lifeof the fuse are desired.

Providing less expensive fuse monitoring systems that are configured tohandle high current and high battery voltages in state of the art EVpower systems, while still providing acceptable interruption performanceas the fuse element operates at high voltages and monitoring of at leastthe fuse element continues to be challenging. Fuse manufacturers and EVmanufactures would each benefit from less expensive and less complexfuse monitoring systems. While EV innovations are leading the marketsdesired for smaller, more affordable higher voltage fuses and monitoringsystems, the trend toward smaller, yet more powerful, electrical systemstranscends the EV market. A variety of other power system applicationswould undoubtedly benefit from less complex and more affordable fusemonitoring systems. The demands imposed on electrical fuses by EV powersystem applications, however, presents particular challenges that mayshorten a service life of the electrical fuses and that may result inunplanned downtime of the vehicle without additional monitoring systemsto facilitate prediction of these failure events. Improvements areneeded to resolve longstanding and unfulfilled needs in the art.

Inventive systems and methods are disclosed below wherein fusemonitoring is achieved at least in part by monitoring parameters such asenvironmental conditions/data/parameters and/or electrical performanceparameters/operational parameters or data, and collectively evaluatingthe parameters for a similar fuse element to assess an operative stateof the fuse, a performance of the fuse, and a remaining service life ofthe fuse. The environmental conditions or parameters may include ambienttemperature, humidity, and/or pressure to which the fuse is exposed. Theenvironmental conditions may also include vibration, acceleration,and/or shock to which the fuse is exposed. As used herein, “shock” mayrefer to impact force, as well as sudden change in acceleration orvelocity. The electrical performance parameters include voltage,current, resistance, and/or temperature of the fuse attributable tocurrent loads.

For the purposes of this description, the term “service life” is made inreference to the useful circuit protection life of the fuse, when in useas part of an electrical power system—i.e., the period of time in whichthe fuse functions as designed in protecting against overcurrent and/orshort circuit conditions. Service life may be characterized in terms ofremaining life/lifetime, remaining useful life/lifetime, consumedlife/lifetime, consumed useful service life/lifetime, or simply as lifeexpectancy, or life/lifetime until fuse replacement is recommended orrequired due to predicted end of life concerns in the power system thatis being protected. As such, an appropriate life/lifetime warning oralert can be provided to an owner/driver of an EV, for example, as thepredicted end of life approaches but in advance of actual fuse failureto proactively manage replacement of the fuse and avoid undesirableoperation of the fuse while the EV is in use.

Described below are exemplary embodiments of systems and methods thatfacilitate a computationally-efficient and cost effective monitoringperformance and estimation of a service life of an electrical fuseelement. Monitoring of the performance of the fuse and advancedknowledge of the remaining service life of the fuse enables an operatorto replace a fatigued fuse prior to failure and/or manage inventory ofnew fuse elements. Predicted fuse service life, as explained in detailbelow, will be achieved, at least in part, by measuring real-timeparameters associated with the fuse (e.g., temperature, humidity,vibrations, shock, current, voltage, etc.) and applying a model to themeasured real-time parameters to predict the remaining service life ofthe fuse. In some embodiments, the system may provide alerts andnotifications concerning the measured parameters, the performance of thefuse and/or the predicted service life of the fuse to a user or anoperator associated with the fuse. For example, the system communicatesthe measured parameters, fuse performance, and/or the remaining servicelife to one or more remote computing devices. Method aspects will be inpart apparent and in part explicitly discussed in the followingdescription.

In some embodiments, the systems and methods described herein may beused to determine if the fuse is functioning or if the fuse has failed.If the fuse has failed, the systems and methods may be used to determineone or more reasons, or causes, that contributed to, or caused thefailure of the fuse. For example, fuse failure may have been caused byshort-circuiting, overloading, and/or the fuse has faulted. In otherexamples, the fuse may have failed because the fuse was exposed toconditions, e.g., environmental conditions, that are not suitable forthe ratings of the fuse. In yet another example, the fuse may havefailed because an incorrect fuse was installed.

In some embodiments, the systems and methods described herein may beused to determine one or more recommendations. The recommendations mayinclude maintenance operations, intervention procedures, and/orinventory analysis. Maintenance operations may include replacement offailed fuses or replacement of fuses prior to failure. Interventionprocedures may include adjusting the conditions to which the fuse isexposed. For example, it may be recommended to cool an area near thefuse, or alternatively, turn off one or more electrical components inelectrical connection with the fuse. In EV applications, it may berecommended to turn off the EV until safer fuse conditions can beobtained in order to avoid sudden fuse failure. Inventory management mayinclude confirming that fuses are in stock, to be ready to replace oneor more fuses that are predicted to fail in the near future. Inaddition, inventory management may include ordering one or more newfuses and/or shipping fuses from one storage facility to another. Theone or more recommendations encompass any suitable recommendations thatenables an optimized continued fuse usage while minimal downtime causesby fuse failure.

While the present disclosure describes systems, methods, and apparatusfor monitoring fuses used in EV applications and embodiments of thepresent disclosure are described in the context of a particular type andrating of a fuse to meet the needs of the exemplary EV application, thebenefits of the disclosure are not necessarily limited to EVapplications or to the particular type or rating of fuses described.Rather the benefits of the disclosure are believed to more broadlyaccrue to many different power system applications generating othercurrent profiles. Systems and methods described herein may also be usedin other electric-powered vehicles such as boats or planes ornon-vehicle power systems that are likewise susceptible to shock,vibration, and humidity. The systems and methods can also be practicedin part or in whole to monitor any types of fuses used for anyapplication and in any environment having similar or different ratingsthan those discussed herein. For example, and without limitation, thefuse monitoring systems and methods described herein may be used tomonitor fuses that are used in aerospace applications, automotiveapplications, and water related vehicles, e.g., submarines, boats, andother types of watercrafts. The fuses described below are thereforediscussed for the sake of illustration rather than limitation.

FIG. 1 is a schematic diagram of a fuse monitoring system 100 (referredto herein as system 100) for monitoring a fuse 110 according to theexemplary embodiments of the present disclosure. FIG. 2 is a blockdiagram of the system 100 shown in FIG. 1 . In the illustratedembodiment, the fuse 110 is shown to be used with an EV 112. The fuse110 and the EV 112 is illustrative only, and does not limit the scope ofthe system 100 to a particular type of fuse or particular EVconfiguration (e.g., car, crossover, sport utility vehicle, truck,etc.). As described in further detail herein, the system 100 includesone or more adjustable features that enable the system 100 to becustomized to monitor various types of fuses (e.g., cartridge type fuse,D-type fuse, and link-type, etc.) used in various applications (e.g.,transformers, motors, commercial settings, industrial settings, andcomputer applications, etc.).

The system 100 includes a fuse monitoring assembly 116 (referred toherein as assembly 116) which is positioned in proximity to the fuse110. The assembly 116 includes a processor 118 that is communicativelycoupled to one or more sensors 120. The one or more sensors 120 measure,in real-time, one or more parameters associated with the fuse 110. Inthe exemplary embodiment, the one or more measured parameters, measuredby the sensors 120, include environmental conditions (e.g., ambienttemperature, humidity, and/or pressure) and/or fuse performanceparameters (e.g. fuse temperature, current, voltage, and/or resistance)associated with the fuse 110, as described in further detail herein.While one fuse 110 and one monitoring assembly 116 are shown in FIG. 1 ,it is understood that the system 100 is scalable to any number of fusesthat are desirably monitored in the EV power system by adding additionalmonitoring assemblies 116.

The system 100 further includes a fuse monitoring computing device 130that is communicatively coupled to the assembly 116. In the exemplaryembodiment, the sensors 120 collect sensor data 132 related to the oneor more measured parameters associated with the fuse 110 and theassembly 116 transmits the sensor data 132 to the computing device 130.The computing device 130 analyzes, processes, and/or evaluates thesensor data 132 for the purpose of monitoring the fuse 110. Thecomputing device 130 may include a user interface 134 for displayingsensor data 132 and/or analyzed sensor data 132. The user interface 152may include a graphical interface with interactive functionality, suchthat a user or an operator may interactively request information fromthe system 100. In some embodiments, the computing device 130 isconnected to the assembly 116, e.g., the processor 118, via a USBconnection. For example, the processor 118 may evaluate the sensor datato create one or more outputs to be displayed on the computing device130, e.g., via the user interface 134. The computing device 130 may beconnected to the processor 118 and/or the sensors 120 using any suitableconnection. In some embodiments, the user computing device 150 may beconnected to the processor 118 and/or the sensors 120 using the USBconnection.

In the exemplary embodiment, the computing device 130 evaluates thesensor data 132 using modeling techniques, as described in furtherdetail herein, to determine the remaining fuse service life. In someembodiments, the computing device 130 compares the sensor data 132 toone or more corresponding predetermined threshold values to evaluate theperformance of the fuse 110. In some embodiments, the computing device130 may determine, based at least in part on the sensor data 132, one ormore fuse metrics. The fuse metrics may include an average of the sensordata 132 over a period of time and/or a rate of change of the sensordata 132 over a period of time. In another embodiment, the computingdevice 130 filters and/or normalizes the sensor data 132. The computingdevice 130 may evaluate the sensor data 132 using any suitablemethodology or technique that enables the system 100 to function asdescribed herein.

The system 100 also includes a historical fuse database 140. Thecomputing device 130 is communicatively coupled to the historical fusedatabase 140 and stores in the historical fuse database 140 a pluralityof historical fuse records 142. The historical fuse records 142 are eachassociated with a historical fuse, i.e., a fuse that has been retired,replaced, and/or has failed. Each of the historical fuse records 142 mayinclude a fuse type, a fuse application (i.e., the use of the historicalfuse, e.g., an EV application, or an industrial application, etc.), ahistorical fuse service life, and/or historical measured fuseparameters. Historical measured fuse parameters may include historicalshock data, historical ambient temperature data, historical ambienthumidity data, historical vibrations data, historical current data,historical voltage data, historical fuse temperature data, and/orhistorical resistance data. The historical fuse records 142 may alsoinclude one or more metrics determined by the computing device 130. Forexample, the computing device 130 may determine a historical averageand/or rate of change of one or more of the historical measured fuseparameters to be included within the historical fuse record 142. Thehistorical fuse service life may include an amount of time that the fuse110 was in use prior to fuse failure. The historical fuse service lifemay include a number of service cycles prior to fuse failure. Thecomputing device 130 may create the historical fuse record 142 using anysuitable data such that the system 100 is configured to function asdescribed herein.

The computing device 130 may also store the sensor data 132 and/or theone or more determined metrics associated with the fuse 110 within thehistorical fuse database 140. In some embodiments, the assembly 116 isalso communicatively coupled to the historical fuse database 140 suchthat the assembly 116 may transmit the sensor data 132 to be storedwithin the historical fuse database 140.

In the exemplary embodiment, the system 100 further includes a usercomputing device 150 that is communicatively coupled to the computingdevice 130. The user computing device 150 may include a mobile cellulardevice, a laptop computer, a desktop computer, a tablet computer, andthe like. The user computing device 150 includes a user interface 152.The user interface 152 may include a graphical interface withinteractive functionality, such that a user or an operator mayinteractively request information from the system 100. In someembodiments, the user computing device 150 is also communicativelycoupled to the assembly 116. The user computing device 150 is associatedwith a computing device that is accessible to a user (e.g., an operatorof the EV 112, a worker within an industrial environment, and/or anypersons associated with the monitoring of the fuse 110) enabling theuser to monitor the fuse 110 in real-time. Specifically, the computingdevice 130 transmits a plurality of messages 154 to the user computingdevice 150. The messages 154 include information related to the fuse110. In the exemplary embodiment, the message 154 includes thedetermined remaining service life of the fuse 110. The messages 154 mayalso include the sensor data 132 (i.e., the measured fuse performanceparameters or the measured environmental conditions). The message 154may include a maintenance recommendation. The computing device 130transmits any data and/or information that enables system 100 tofunction as described herein.

In the exemplary embodiment, the user computing device 150 may displayat least a portion of the contents of the messages 154 using the userinterface 152. In some embodiments, the user computing device 150 isassociated with the EV 112. For example, the user computing device 150may be integral to the EV 112 and communicatively coupled to a dashboarddisplay (not shown) or integrated into an infotainment system of thevehicle. The dashboard display and/or infotainment display may beconfigured to present at least a portion of the contents of the messages154 received from the computing device 130. Accordingly, real-timemonitored fuse status such as measured parameters, calculated metrics,and predicted remaining fuse service life may be presented to a user whois operating the EV 112 or to passengers through vehicle systems.

In the exemplary embodiment, the computing device 130 transmits themessages 154 to the user computing device 150 as frequently as necessaryto enable the system 100 to function as described herein. In otherwords, the computing device 130 transmits messages 154 with sufficientfrequency to ensure the user computing device 150 is kept up to datewith the real-time status of the fuse(s) being monitored (e.g.,performance and/or remaining service life of the fuse(s) 110). Thecomputing device 130 may transmit messages 154 periodically at scheduledtime intervals. The computing device 130 may also transmit the messages154 in response to the computing device 130 processing, evaluating,and/or analyzing the sensor data 132. For example, the computing device130 may periodically determine the remaining service life, and then maycompare the determined remaining service life to a service lifethreshold. When the computing device 130 determines that the determinedremaining service life passes the service life threshold, the computingdevice 130 may transmit the message 154 to the user computing device150, the message 154 including a warning that the determined remainingservice life is below the service life threshold.

In the exemplary embodiment, the assembly 116, the computing device 130,and the user computing device 150 are connected as an Internet of Things(IoT) 122, where the assembly 116 includes sensors and processors andcommunicates with the computing device 130 and/or the user computingdevice 150 through Internet or other communication networks formed bywired or wireless communication. The assembly 116, the computing device130, and the user computing device 150 may communicate with any otherdevice that is also connected to the IoT 122. The one or more sensors120 may also be wirelessly communicatively coupled to the processor 118,such that the one or more sensors 120 may transmit sensor data 132 tothe processor 118 wirelessly. In other embodiments, the one or moresensors 120 may transmit sensor data 132 to the processor 118 through awired connection. The computing device 130, the assembly 116, and theuser computing device 150 may be connected to the IoT 122 through awired or a wireless connection, supervisory control and data acquisition(SCADA), or any monitoring or control device. Alternatively, the fusemonitoring assembly 116 may communicate with the computing device 130directly through radio frequency (RF) communication such as short-waveRF communication. Accordingly, data (e.g., sensor data 132 oranalyzed/processed sensor data 132) may be wirelessly transmitted fromthe sensors 120 to the processor 118 or from the assembly 116 to thecomputing device 130. Furthermore, data may be wirelessly transmittedfrom the computing device 130 to the user computing device 150.

The system 100 configured as IoT 122 is advantageous in saving laborcost and reducing lead time. For example, with the system 100,inspection or maintenance may be reduced because the operation statusand life of the assembly 116 is available through the computing device130 and/or the user computing device 150. Further, lead time, the timeneeded to locate faulty fuses, is reduced because the system 100provides information of and alerts faulty fuses, and also predicts theend of lives the fuses such that failure of the fuses may be soonexpected.

The assembly 116, the computing device 130, and the user computer device150 are separate but are communicatively connected enabling the assembly116, the computing device 130, and the user computing device 150 toexchange information. However, it should be understood that thecomputing device 130, the user computing device 150, and the assembly116 may be integrated into a single computing device with all thefunctionality of each of the computing device 130, the user computingdevice 150, and the assembly 116, separately, without deviating from thesubstantially from the present disclosure.

In the exemplary embodiment, at least one of the fuse monitoringassembly 116, the computing device 130, and the at least one sensorcommunicates with a mobile tower, a cell tower, or a base transceiverstation (BTS). The BTS includes antennas and electronic communicationequipment, and create a cell in a cellular network or atelecommunications network, which is used for transmission of voice,data, and other types of content. The BTS may be in a telecommunicationsnetwork such as 3G, 4G, or 5G networks

In some embodiments, the computing device 130 includes a processor-basedmicrocontroller including a processor and a memory device whereinexecutable instructions, commands, and control algorithms, as well asother data and information needed to satisfactorily operate the fusemonitoring system 100, are stored. The memory device may be, forexample, a random access memory (RAM), and other forms of memory used inconjunction with RAM memory, including but not limited to flash memory(FLASH), programmable read only memory (PROM), and electronicallyerasable programmable read only memory (EEPROM).

As used herein, the term “processor-based” microcontroller shall refernot only to controller devices including a processor or microprocessoras shown, but also to other equivalent elements such as microcomputers,programmable logic controllers, reduced instruction set circuits (RISC),application specific integrated circuits and other programmablecircuits, logic circuits, equivalents thereof, and any other circuit orprocessor capable of executing the functions described below. Theprocessor-based devices listed above are exemplary only, and are thusnot intended to limit in any way the definition and/or meaning of theterm “processor-based.”

In further reference to FIG. 2 , the assembly 116, for use within the EV112, includes any number of sensors 120 enabling the system 100 tofunction as described herein. In the exemplary embodiment, the one ormore sensors 120 includes environmental sensors 160 that are configuredto measure the environmental conditions of the environment in which thefuse 110 locates, e.g., ambient temperature, ambient humidity, ambientpressure, vibrations, and shock. In the exemplary embodiment, theassembly 116 includes an ambient temperature sensor 162 configured tomeasure the temperature in proximity to the fuse 110 and an ambienthumidity sensor 164 configured to measure the humidity in proximity tothe fuse 110. In some embodiments, the one or more sensors may alsoinclude an ambient pressure sensor. In the exemplary embodiment, theassembly 116 also includes a vibration sensor 166 configured to measurevibration and a force sensor 168 configured to measure shock to whichthe fuse 110 may be exposed. The vibration sensor 166 is an inertialsensor or an accelerometer which detects accelerations and/or vibrationsof the fuse 110. In some embodiments, the vibration sensor 166 is usedto detect and measure shock and/or impact experienced by the fuse 110.The force sensor 168 may include a load cell, a strain gauge, and/or aresistor.

The environmental sensors 160 which are configured to measureenvironmental conditions may be selectively positionable relative to thefuse 110, such that the environmental sensors 160 may be arranged insufficient proximity to the fuse 110 so that the environmental sensors160 measure environmental conditions to which the fuse 110 is exposed.Positioned in proximity refers to a relative spatial position betweenthe fuse 110 and the one or more sensors 120. In some embodiments, theenvironmental sensors 160 may be mounted within 30 cm of the fuse 110(i.e., within a range of 0 cm to 30 cm from the actual fuse location),for example. In other example embodiments, the environmental sensors 160may be mounted within 15 cm of the fuse 110 (i.e., within a range of 0cm to 15 cm from the actual fuse location). In other embodiments, theenvironmental sensors 160 are positioned in sufficient proximity to thefuse 110 to enable the one or more environmental sensors 160 to measurethe environmental conditions to which the fuse 110 is exposed.

In the exemplary embodiment, the one or more sensors 120 includeselectrical sensors 170 that are configured to measure fuse performanceparameters associated with the fuse 110 e.g., fuse temperature,resistance (e.g., resistance across the fuse), input current, outputcurrent, and/or voltage across the fuse 110. The fuse temperature andthe environmental temperature may be correlated but are two separatemeasurements. The environmental, also referred to as ambient,temperature is the temperature to which the fuse 110 is exposed, whilethe fuse temperature is the operating temperature of the fuse 110,itself, which may be heated by both the environmental temperature andjoule heating attributable to current flowing through the fuse 110. Inthe exemplary embodiment, the system 100 includes resistance sensor 172configured to measure resistance, a voltage sensor 174 configured tomeasure voltage across the fuse, a current sensor 176 configured tomeasure at least one of input and output current of the fuse 110, andfuse temperature sensor 178 configured to measure fuse temperature.Determining resistance using the resistance sensor 172 may includedetermining the resistance using sensor data 132 collected from thevoltage sensor 174 and/or the current sensor 176. The temperature,current, voltage, and resistance sensors 172, 174, 176, and 178 are eachoperably coupled to the fuse 110 for direct measurement of the fuseperformance parameters. In some embodiments, a resistance sensor is notincluded, and the resistance is calculated using data collected from thevoltage sensor 174 and/or the current sensor 176 using the formula thatResistance is equal to Voltage divided by Current.

As described above, the processor 118, of the assembly 116, iscommunicatively coupled to each of the one or more sensors 120. In someembodiments, the assembly 116 may include an assembly memory 180 that iscommunicatively coupled to the processor 118 and/or the one or moresensors 120. The processor 118 may collect the sensor data 132 and storethe sensor data 132 within the assembly memory 180, prior totransmitting the sensor data 132 to the computing device. In theexemplary embodiment, the assembly 116 may include an assemblytransmitter 182 that the processor 118 uses to transmit the sensor data132, in-real time, to the computing device 130. The sensor data 132 maybe periodically or continuously transmitted to the computing device 130.The processor 118 may transmit the sensor data 132 at a rate that isapproximately equal to a sampling rate of the one or more sensors 120.For example, the ambient temperature sensor 162 may sample ambienttemperature every second, for example, and accordingly, the processor118 transmits the sensor data 132 to the computing device 130 everysecond. In some embodiments, the processor 118 may store the sensor data132 within the assembly memory 180 and then periodically, at scheduledtime increments, transmit the sensor data 132 to the computing device130 in batches.

In some embodiments, the processor 118 may compare the sensor data 132to one or more corresponding predetermined thresholds. When theprocessor 118 determines that the sensor data 132 has exceeded thepredetermined threshold, the processor 118 may initiate transmission ofthe sensor data 132, and/or a warning message, to the computing device130. When the processor 118 determines that one or more thresholds havebeen crossed, the processor 118 may override a scheduled periodictransmission of the sensor data 132. The processor 118 may transmit thesensor data 132 to the computing device 130 as frequently as necessaryto enable the system 100 to function as described herein.

In the exemplary embodiment, the computing device 130 builds a trainingdataset by retrieving a set of historical fuse records 142 (e.g.,hundreds, thousands, tens of thousands, hundreds of thousands, etc. ofhistorical fuse records 142) from the historical fuse database 140. Eachof the historical fuse records includes a fuse type, a fuse application,a fuse service life, historical fuse data collected by the one or moresensors 120. In some example embodiments, the historical fuse recordsmay include one or more metrics that are calculated by the computingdevice. For example, the computing device may calculate a historicalaverage temperature, humidity, and/or pressure, to be included withinthe historical fuse record. The fuse service life may include an amountof time that the fuse was in use before the fuse failed.

The training dataset may be used to train a fuse model. In someembodiments, the computing device 130 builds fuse specific trainingdatasets which include a plurality of historical fuse records eachassociated with a specific type of fuse or a specific type of fuseapplication. For example, the computing device 130 may build a EVtraining dataset which includes a plurality of historical fuse records142 associated with a plurality of fuses that were used in EVapplications. In yet another embodiment, the computing device 130 maybuild an industrial training dataset which includes a plurality ofhistorical fuse records 142 associated with a plurality of fuses thatwere used in an industrial environment. In yet another example, thecomputing device 130 may build a global training dataset which includesa plurality of historical fuse records 142 associated with a pluralityof fuses that were used for various applications.

The computing device 130 generates a fuse model based on the one or moretraining datasets using machine learning techniques. More specifically,the computing device 130 uses the training dataset to train the fusemodel, such as to develop a set of rules or conditions that may beapplied to real-time sensor data 132, i.e., inputs, and generate outputsassociated with the fuse.

In the example embodiment, the computing device 130 includes a modelingcomponent. The modeling component includes a computer-executableinstruction for using at least a machine learning algorithm. Somemachine learning algorithms used by the modeling component includeartificial neural network and Bayesian statistics. Other machinelearning models used by the modeling component may include, for example,decision tree, inductive logic, learning vector quantization, ordinalclassification, and information fuzzy networks (IFN).

As used herein, “machine learning” refers to statistical techniques togive computer system the ability to “learn” (e.g., progressively improveperformance on a specific task) with data, without being explicitlyprogrammed for that specific task. “Artificial intelligence” refers tocomputer-executed techniques that allow a computer to interpret externaldata, “learn” from that data, and apply that knowledge to a particularend. Artificial intelligence may include, for example, neural networksused for predicative modeling.

The computing device 130 applies one or more inputs into the model todetermine or more outputs. In the exemplary embodiment, the one or moreinputs are fuse data associated with the fuse 110, such as the sensordata 132, collected in real-time, by the plurality of sensors 120. Fusedata include operational data such as current, voltage, resistance,and/or temperature of the fuse 110 and environmental data associatedwith the fuse 110 such as shock, vibration, ambient temperature, and/orhumidity of the environment in which the fuse 110 locates. Inputs mayalso include other fuse data associated with the fuse 110, such as fuseclass, fuse maximum current rating, interrupting rating, currentlimiting, and a general use of the fuse. Fuse data may also include ifthe fuse 110 is fast acting or time-delayed. In some embodiments, thecomputing device 130 may calculate inputs, based at least in part onsensor data 132, to be applied to model. For example, the computingdevice 130 may calculate an average ambient temperature over a period oftime. The computing device 130 may use the average ambient temperatureas an input into the model.

The sensor data 132 may be received by the computing device 130, inreal-time, e.g., continuously and/or periodically, and the computingdevice 130 may apply the model to the sensor data 132, continuously(e.g., at a sampling rate of the plurality of sensors 120) and/orperiodically, such that the output of the model reflects the real-timestate of the fuse. For example, the computing device 130 may receivefrom the processor 118, real-time ambient temperature data, collected bythe ambient temperature sensor 162. The computing device 130 may inputthe real-time ambient temperature data into the model periodically atscheduled time intervals, e.g., every minute, every five minutes, everyhour, every three hours, for example, to determine the remaining servicelife of the fuse 110.

The computing device 130 may apply the inputs to the model to determineone or more outputs. In the exemplary embodiment, the one or moreoutputs may include a remaining service life of the fuse associated withhow long the fuse should be used before the fuse should be replaced orbefore the fuse will fail. The remaining service life of the fuse may bea remaining service life time (e.g., ten hours remaining service life),a number of remaining service life cycles (e.g., the fuse may be usedten more times before replacement is recommended). In some embodiments,the output may include a suggested fuse classification. For example, thecomputing device 130 may determine, using the model and the inputs, fora fuse having a first classification and used in a specific application,that a different fuse classification may be better suited for theapplication. In some embodiments, the output may include a determinationof whether the fuse 110 is no longer functioning, e.g., the fuse 110 hasfailed. For example, the output may include a determination that thefuse 110 has short-circuited, overload, and/or has faulted. In otherexamples, the output may include a determination that the fuse 110 isnot suitable for a particular application, e.g., a fuse was incorrectlyinstalled or a wrong type of fuse was installed.

In some embodiments, a physical model is used to predict life of a fusebased on environmental data and/or operation data. For example, aphysical model may include empirical relations between fuse data andlife of the fuse derived based on historical data, physical relations,or rules such as Miner's rule based on the cyclic characteristics of theoperational data such as current, voltage, and/or resistance. Thehistorical data may be used to fit and optimize the model. In oneexample, a plurality of thresholds on environmental data and/oroperation data may be derived based on historical data and used topredict the life of the fuse. Alternatively, a combination of a physicsmodel and a machine-learning model is used to predict life of a fusebased on the measured data. For example, the prediction may be startedwith a physical model when training or historical data is lacking orinsufficient to train a machine-learning model to achieve a desiredconfidence level. The real-time data and predicted life may be used totrain the machine-learning model. As the confidence level of themachine-learning model increases, the machine-learning model may becomethe main model in life prediction.

Systems and methods described herein predict the remaining life based onoperation data such as resistance, current, voltage, and/or temperatureof the fuse, as well as environmental data such as ambient temperature,shock, vibration, and/or humidity of the ambient environment of thefuse. The accuracy of the predicted life is increased becauseenvironmental data and operation data both play a role in affecting thefuse's life.

FIG. 3 is a perspective view of an exemplary embodiment of the fusemonitoring assembly 116. The fuse monitoring assembly 116 illustrated inFIG. 3 is shown to be connected to a fuse housing 200 which supports oneor more fuses 110 (visible in FIGS. 5 and 6 ) that are monitored by theassembly 116. In reference to FIG. 4 , the assembly 116 includes ahousing 202 having an upper housing 204 and a lower housing 206. Theupper housing 204 and the lower housing 206 may be selectively coupledtogether, using any suitable fasteners or fastening techniques, todefine a housing cavity 208. The upper housing 204 and lower housing 206may be selectively coupled together such that a user may separate theupper housing 204 from the lower housing 206 to access the contents ofthe housing cavity 208, as is described in further detail herein. Insome embodiments, the upper housing 204 and the lower housing 206 arerotationally connected. In reference to FIG. 4 , in this illustratedembodiment, the assembly 116 is configured to monitor three fuses 110.In other embodiments, the fuse monitoring assembly 116 may be configuredto monitor any number of fuses 110, including a single fuse (i.e., oneand only one fuse) as desired.

As described above, the assembly 116 is customizable and modular suchthat the assembly 116 is configured to monitor various types of fusesused in various applications without changing the design of the assembly116. For example, in the illustrated embodiment, the housing 202 may besized and shaped such that the assembly 116 is suitable to beselectively coupled to a fuse housing 200 having any shape or size. Inthe illustrated embodiment, the housing 202 includes one or more clips210 that are sized and shaped to be received within an opening 212formed on the fuse housing 200. The clips 210 include a bias mechanismenabling the clips 210 to be frictionally engaged with the fuse housing200 when the clips 210 are disposed within the openings 212 (see FIG. 6), such that the housing 202 is selectively coupled to the fuse housing200. In other embodiments, housing 202 may be selectively connected tothe fuse housing 200 using any suitable fasteners. In some embodiments,the assembly 116 is configured to be retrofitted to existing fusehousings 200. For example, the fuse monitoring assembly 116 may includeany number of sensors 120 such that the assembly 116 is configured tomonitor any number of the fuses 110 contained within the fuse housing200.

Furthermore, different applications the fuse 110 may be exposed todifferent conditions, as such the assembly 116 may be customizable suchthat the assembly 116 may be configured to monitor a specific type offuse having a specific fuse classifications and/or a specific fuseapplication. In the illustrated embodiment, the assembly 116 iscustomized to monitor the fuse 110 used in the EV 112. In an alternativeembodiment, the assembly 116 may be customized to monitor a fuse used inan industrial application. The assembly 116 may also be customized tomonitor a specific classification of fuse. For example, the assembly 116may include sensors 120 that are rated to measure a range of current,voltage, and/or resistance that the fuse 110 is likely to experience. Amodular assembly 116 allows reduction of costs and simplification ofmaintenance and updates. For example, if a fuse has already beeninstalled on site, the modular assembly 116 is configured to monitor thefuse 110 without the need to replace the fuse and the fuse housing 200.

In further reference to FIG. 4 , the housing cavity 208 stores thereinthe processor 118, and the plurality of sensors 120. The processor 118and the plurality of sensors 120 may be connected to at least one of theupper housing 204 and/or the lower housing 206. The housing 202 isselectively coupled to the fuse housing 200 such that the plurality ofsensors 120 are arranged in proximity to the fuse 110. In theillustrated embodiment, the assembly 116 includes both the environmentalsensors 160 and the fuse performance electrical sensors 170. Inparticular, in the exemplary embodiment, the assembly 116 includes theambient temperature sensor 162, the humidity sensor 164, the vibrationsensor 166, and the force sensor 168. The assembly 116 also includes thevoltage sensor 174 and the current sensor 176. The housing 202 includesan opening 216 in proximity to the ambient temperature sensor 162 andthe humidity sensor 164. The opening allows the ambient temperaturesensor 162 and the humidity sensor 164 to be exposed to theenvironmental conditions outside of the housing 202. In some otherembodiments, the ambient temperature sensor 162 and the humidity sensor164 may be coupled to the exterior of the housing 202. The contentsstored within the housing cavity 208, i.e., the processor 118 and theplurality of sensors 120, are accessible without requiring the assembly116 to be disconnected from the fuse 110 and/or the fuse housing 200.More specifically, the assembly 116 may be connected to one or morefuses 110 and/or the fuse housing 200, and subsequently, an operator mayaccess the contents of the housing cavity 208 by opening the housing202. The housing 202 may be opened by decoupling or disengaging theupper housing 204 from the lower housing 206. Alternatively, the housing202 may be opened by disconnecting a portion of the upper housing 204from the lower housing 206 and then rotating the upper housing 204relative to lower housing 206. Opening of the housing 202 provides anoperator with a readily access to the contents stored within the housingcavity 208, without requiring the operator to disengage the housing 202,in its entirety, from the fuse 110 or the fuse housing 200. An operatormay open the housing 202 to perform maintenance operations, such as,inspect, replace, or repair one or more of the contents within thehousing cavity 208. For example and without limitation, an operator mayopen the housing 202 to replace the ambient temperature sensor 162.Opening of the housing 202 allows a maintenance procedure to beperformed without disruption of the fuses 110.

The fuses 110, being monitored by the assembly 116, are accessible bythe removal of the lower housing 206 from the fuses 110 and/or the fusehousing 200. In the exemplary embodiment, the fuses 110 are accessiblewithout requiring opening of the housing 202. Stated another way, anoperator may readily access the fuses 110 that are being monitored bydisconnecting the lower housing 206, without requiring the operator toopen the housing 202. Removal of the housing 202, to access the fuses110 without opening the housing 202, reduces exposure of the contents ofthe housing cavity 208 from potential harmful conditions, e.g., exposureof the one or more sensors 120 stored within the housing cavity 208, todebris or liquids. Furthermore, the assembly 116 may be disconnectedfrom the fuse 110 and/or fuse housing 200 for replacement and/or repairof the assembly 116, for example for an upgrade (e.g., softwareupgrade). In yet another example, the assembly 116 may be replaced withan alternative assembly 116 having one or more of the plurality ofsensor 120 rated for specific conditions and/or environmentalconditions. For example, for the assembly 116 used in an EV 112 thattypically travels in a climate in which has an annular mean temperatureof 30°, for example, is now used in a climate in which the annular meantemperature is 10° C. Accordingly, the assembly 116 may be exchangedwith another assembly 116 having an ambient temperature sensor that israted for the climate of the location of the EV 112.

The housing 202 defines a first port 218 that is sized and shaped suchthat a cable (e.g., USB connection or any suitable connection, notshown) may be passed through the first port 218 to be operably coupledto the processor 118 contained within the housing 202. The housing 202also includes a second port 220 that is sized and shaped such that adisplay cable may be passed through the second port 220 to be operablycoupled to the processor 118 contained within the housing cavity 208.The housing 202 may include any suitable number and/or configuration ofports that allow access to one or more components stored within thehousing cavity 208.

In the exemplary embodiment, the upper housing 204 and the lower housing206 are sized and shaped such that the housing cavity 208 is a suitablesized and shaped to accommodate the dimensions of the plurality ofsensors 120 stored therein, while maintaining a small and compactoverall profile of the housing. For example, the upper housing 204 andthe lower housing 206 are not oversized and the plurality of sensors 120fit within the housing cavity 208 with a limited clearance C, visible inFIG. 6 , between the plurality of sensors 120 and the upper housing 204and the lower housing 206. The clearance C may be, for example, between0-2.5 mm. In some embodiments, the clearance C is not uniform. In someembodiments, the sensors 120 are supported by or in contact with thelower housing 206 and the clearance C is defined between the sensors 120and the upper housing 204.

In reference to FIG. 6 , in the exemplary embodiment, the housing 202has one or more portions 229. Each of the portions 229 are sized andshaped to accommodate the size and shape of the contents of the portion229. In the exemplary embodiment, the upper housing 204 includes atleast one of a first portion 230 and a second portion 232. The firstportion 230 stores therein the plurality of voltage sensors 174.Accordingly, the first portion 230 has a first height H₂₃₀ and a firstwidth W₂₃₀ that is suitable to accommodate the dimensions of theplurality of the voltage sensors 174 with minimal clearance between thevoltage sensors 174 and the first portion 230. In other words, the firstportion 230 is not oversized, but sized such that the voltage sensors174 fit within the first portion 230. The second portion 232 storestherein at least one of the environmental sensors 160. The secondportion 232 includes a second height H₂₃₂ and a second width W₂₃₂. Thesecond height H₂₃₂ and the second width W₂₃₂ are sized to accommodatethe dimensions of the environmental sensors 160 with minimal clearancebetween the environmental sensors 160 and the second portion 232. Thesecond portion 232 may include the opening 216.

In the illustrated embodiment, at least one of the environmental sensors160 generally has smaller dimensions than that of one of the voltagesensors 174. Accordingly, the height H₂₃₂ of the second portion 232 issmaller than the height H₂₃₀ of the first portion 230. Additionally,and/or alternatively, the number of voltage sensors 174 are proportionalto the number of fuses 110 that are monitored by the assembly 116. Asdescribed above in the illustrated embodiment, there are three fuses 110that are being monitored, and accordingly, there are three voltagesensors 174. On the other hand, there is only one of each environmentalsensor 160 for all fuses 110. Accordingly, the first portion 230 and thesecond portion 232 are of different sizes, shapes, and/or profiles toaccommodate both the number of the sensors 120 and the size of thesensors 120 that are stored therein.

In other embodiments, the housing 202 may have any number of portions229 that are sized and shaped differently to accommodate the contents ofthe portion 229 with minimal clearance. Minimal clearance C between thecontents of the assembly 116 and each of the portions 229 allows theassembly 116 to have a reduced overall size suitable for installation inthe tight and generally compact conditions presented in the EV 112. Inother embodiments, the portion 229 may have any suitable size and shapethat enables the assembly 116 to function as described herein.

In some embodiments, the assembly memory 180 and the transmitter 182 areformed integrally with the processor 118. The assembly 116 may includeany other suitable electronic components that enable the system 100 tofunction as described herein. For example, in the exemplary embodiment,the assembly 116 includes one or more voltage relays 224.

FIG. 6 is a cross-sectional view of the assembly 116 coupled to a fusehousing 200 for monitoring the fuse 110 stored therein. Thecross-sectional view illustrates the connection of the voltage sensor174 and the fuse temperature sensor 178 which is configured to monitorthe temperature of the fuse 110. The voltage sensor 174 includes a firstlead 226 and second lead 228. The first lead 226 and second lead 228 areoperably coupled to a first and second terminal of the fuse 110,enabling the voltage sensor 174 to measure the voltage across the fuse110. In other words, the voltage sensor 174 is operably coupled inparallel to the fuse 110 to detect the voltage across the fuse 110. Thefuse temperature sensor 178 is coupled to the fuse 110, i.e., in contactwith the fuse 110, and/or in sufficient proximity to the fuse 110. Thelower housing 206 may include one or more openings, not shown, such thatat least a portion of the voltage sensor 174 and the fuse temperaturesensor 178 may extend out of the housing 202 in order to be operablyengaged with the fuse 110.

FIG. 7 is a detailed view of the housing 202 showing the current sensor176 of the assembly 116. The housing 202 supports the current sensor 176which uses a magnetic field to detect the current in the fuse 110. Thecurrent sensor 176 measures the current of the fuse passively, withoutinterrupting the circuit of the fuse 110. In the illustrated embodiment,the assembly 116 includes three current sensor 176 to monitor each ofthe three of the fuses 110. Greater or fewer numbers of current sensors(including one and only one current sensor) could likewise be providedin alternative embodiments).

FIGS. 8A and 8B illustrates a plurality of views of an exemplary userinterface 152, displayed on the user computing device 150. The userinterface 152 enables monitoring of the fuse 110 using the system 100shown in FIG. 1 . In the exemplary embodiment, the user interface 152may be displayed on any suitable user computing device 150 enabling auser to monitor the fuse 110. For example, the user interface 152 may bedisplayed on a dashboard screen or information screen associated withthe EV 112.

In reference to FIG. 8A, a first view 404 of the user interface 152includes a fuse identification number 408 that uniquely identifies thefuse 110 being monitored by the system 100. The user interface 152 alsodisplays one or more fuse details 410 that may be used to identify thefuse 110, such as a fuse class, a fuse rating, and/or any other detailsregarding the fuse 110. For example, in some embodiments, the userinterface 152 may display a location of the fuse 110, an application ofthe fuse 110 (e.g., EV or industrial), and/or an installation date ofthe fuse 110. The user interface 152 may display any suitable fusedetails 410 that enable the system 100 to function as described herein.

In the exemplary embodiment, the user interface 152 displays real-timefuse performance parameters 412 and real-time environmental conditions414 of the fuse 110, measured by the one or more sensors 120. Thereal-time fuse performance parameters 412, including voltage, current,resistance, and fuse body temperature, are graphically displayed usingboth a metered gauge and a digital display. The real-time environmentalconditions 414 of the fuse 110 are digitally displayed. The real-timeenvironmental conditions displayed include ambient temperature, ambienthumidity, and fuse holder vibrations. The user interface 152 alsodisplays the remaining service life 416 using a scale to illustrate apercent remaining service life. The user interface 152 may displayreal-time fuse performance parameters 412 and real-time environmentalconditions 414 of the fuse 110 using any suitable graphical or digitaldisplays. Additionally, the user interface 152 may display any suitabledata that enables system 100 to function as described herein. In someexample embodiments, the user interface 152 may display one or moredetermined metrics, e.g., average ambient temperature.

In some embodiments, the user interface 152 may be interactive, allowinga user to submit one or more query messages to the computing device 130.For example, the user interface 152 may include one or more user inputs,such as buttons, toggles, and/or drop down menus, enabling a user toselect information to be displayed on the user interface 152. Forexample, a user may desire to know a peak voltage at which the fuse 110will fail, the user may engage with the system 100 via the userinterface 152 to obtain this information, i.e., a query message istransmitted from the user computing device 150 to the computing device130 and the computing device 130 may retrieve data that is stored withinthe historical fuse database 140, and then the computing device 130transmits a message to the user computing device 150 to be displayed onthe user interface 152.

FIG. 9 is a top plan view of an exemplary high voltage power fuse 900(e.g., fuse 110) that is designed for use with an EV power system for anEV 112. The fuse 110 may experience a variety of current profiles based,at least in part, on the how the EV 112 is driven. For example, greaterand more frequent accelerations of the EV 112 will cause more currentand voltage fluctuations than less frequent and lower accelerations. Asshown in FIG. 9 , the power fuse 900 of the disclosure includes ahousing 902, terminal blades 904, 906 configured for connection to aline and a load side circuitry, and a fuse element 908 including a fuseelement week-spot 909 that completes an electrical connection betweenthe terminal blades 904, 906. When subjected to predetermined currentconditions, at least a portion of the fuse element 908 melts,disintegrates, or otherwise structurally fails and opens the circuitpath between the terminal blades 904, 906. The load side circuitry istherefore electrically isolated from the line side circuitry to protectthe load side circuit components and the circuit from damage whenelectrical fault conditions occur.

The fuse 900 in one example is engineered to provide a predeterminedvoltage rating and a current rating suitable for use in an electricalpower system of an electric vehicle in a contemplated embodiment. In oneexample, the housing 902 is fabricated from a non-conductive materialknown in the art such as glass melamine in one exemplary embodiment.Other known materials suitable for the housing 902 could alternativelybe used in other embodiments as desired. Additionally, the housing 902shown is generally cylindrical or tubular and has a generally circularcross-section along an axis parallel to length of the terminal blades904, 906 in the exemplary embodiment shown. The housing 902 mayalternatively be formed in another shape if desired, however, includingbut not limited to a rectangular shape having four side walls arrangedorthogonally to one another, and hence having a square orrectangular-shaped cross section. The housing 902 as shown includes afirst end 910, a second end 912, and an internal bore or passagewaybetween the opposing ends 910, 912 that receives and accommodates thefuse element 908.

In some embodiments the housing 902 may be fabricated from anelectrically conductive material if desired, although this would requireinsulating gaskets and the like to electrically isolate the terminalblades 904, 906 from the housing 902.

The terminal blades 904, 906 respectively extend in opposite directionsfrom each opposing end 910, 912 of the housing 902 and are arranged toextend in a generally co-planar relationship with one another. Each ofthe terminal blades 904, 906 may be fabricated from an electricallyconductive material such as copper or silver or suitable metal alloys incontemplated embodiments. Other known conductive materials mayalternatively be used in other embodiments as desired to form theterminal blades 904, 906. Each of the terminal blades 904, 906 is formedwith an aperture 914, 916 as shown in FIG. 3 , and the apertures 914,916 may receive a fastener such as a bolt (not shown) to secure the fuse900 in place in an EV and establish line and load side circuitconnections to circuit conductors via the terminal blades 904, 906.

While exemplary terminal blades 904, 906 are shown and described for thefuse 900, other terminal structures and arrangements may likewise beutilized in further and/or alternative embodiments. For example, theapertures 914, 916 may be considered optional in some embodiments andmay be omitted. Knife blade contacts may be provided in lieu of theterminal blades as shown, as well as ferrule terminals or end caps asthose in the art would appreciate to provide various different types oftermination options. The terminal blades 904, 906 may also be arrangedin a spaced apart and generally parallel orientation if desired and mayproject from the housing 902 at different locations than those shown.

In various embodiments, the end plates 926, 928 may be formed to includethe terminal blades 904, 906 or the terminal blades 904, 906 may beseparately provided and attached. The end plates 926, 928 may beconsidered optional in some embodiments and connection between the fuseelement 908 and the terminal blades 904, 906 may be established inanother manner.

An arc quenching medium or material 932 surrounds the fuse element 908.The arc quenching medium 932 may be introduced to the housing 902 viaone or more fill openings in one of the end plates 926, 928 that aresealed with plugs (not shown). The plugs may be fabricated from steel,plastic or other materials in various embodiments. In other embodimentsa fill hole or fill holes may be provided in other locations, includingbut not limited to the housing 902 to facilitate the introduction of thearc quenching medium 932.

In one contemplated embodiment, the arc quenching medium 932 includesquartz silica sand and a sodium silicate binder. The quartz sand has arelatively high heat conduction and absorption capacity in its loosecompacted state, but can be silicated to provide improved performance.For example, by adding a liquid sodium silicate solution to the sand andthen drying off the free water, silicate arc quenching medium 932 may beobtained with the following advantages.

The arc quenching medium 932 creates a thermal conduction bond of sodiumsilicate to the fuse element 908, the quartz sand, the fuse housing 902and the end plates 926 and 928. This thermal bond allows for higher heatconduction from the fuse element 908 to its surroundings, circuitinterfaces and conductors. The application of sodium silicate to thequartz sand aids with the conduction of heat energy out and away fromthe fuse element 908.

The sodium silicate mechanically binds the sand to the fuse element,terminal and housing tube increasing the thermal conduction betweenthese materials. Conventionally, a filler material which may includesand only makes point contact with the conductive portions of the fuseelement in a fuse, whereas the silicated sand of the arc quenchingmedium 932 is mechanically bonded to the fuse element. Much moreefficient and effective thermal conduction is therefore made possible bythe silicated arc quenching medium 932.

The fuse elements described in the fuse 900 utilize metal stamped orpunched fuse elements, present some concern for EV applicationsincluding the type of cyclic current loads described above. Such stampedfuse element designs whether fabricated from copper or silver or copperalloys undesirably introduce thermal-mechanical strains and stresses onthe fuse element weak-spots 909 such that a shortened service life tendsto result than if the fuse 900 were used in another power system havinga different current load. This shortened fuse service life manifestsitself in the form of nuisance fuse operation resulting from thethermal-mechanical fatigue of the fuse element at the weak-spots 909.

In a contemplated system of the disclosure, the measurement of the fuseresistance may be made with precision by injecting a known currentsacross the fuse element 908. That is, the system may measure thenon-linear fuse resistance while it is in service, and algorithms may bedeveloped to assess the changes in resistance and estimate a temperatureof the fuse element 908 based on the resistance of the fuse 900 and theambient thermal conditions, as will be described further below.

FIG. 10 is a flowchart of an exemplary method 600 of monitoring the fuse110. The method 600 monitors performance of the fuses, as well asenvironmental parameters of the fuses in order to optimize theperformance of the fuses or provide fuses that suited for theenvironment. The method 600 includes installing 602 the assembly 116 inproximity to the fuse 110. The assembly 116 includes the housing 202defining a housing cavity 208 storing the one or more sensors 120therein. Installing 602 may include positioning the assembly 116 inproximity to the fuse 110 and/or connecting the assembly 116 to the fusehousing 200.

In some embodiments, installation 602 includes positioning, in proximityto the fuse 110, the one or more sensors 120 configured to measure theenvironmental conditions to which the fuse 110 is exposed and/or thefuse performance parameters. Specifically, method 600 may includeinstalling 602 the ambient temperature sensor 162, the humidity sensor164, the accelerometer near the fuse 110. Installing 602 includeoperably coupling the fuse temperature sensor, current sensor 176, thevoltage sensor 174, and/or the resistance sensor 172 to the fuse 110.

The method 600 includes receiving 604, at the computing device 130, thesensor data 132 from the one or more sensors 120 of the assembly 116.Receiving 604 the sensor data 132 may include receiving sensor data 132periodically at regularly scheduled interval and/or continuously.

The method 600 includes comparing 606, using the computing device 130,the received sensor data 132 to one or more predetermined thresholds. Insome embodiments, the predetermined threshold is a level of above whichthe fuse 110 is not safe to be in use and needs to be replaced. Thepredetermined threshold is contemplated to be different for variousmeasured parameters, i.e., the environmental conditions and the fuseperformance parameters. In another example, the predetermine thresholdsare ranges, such as ranges of humidity. The measured humidity data mayshow the humidity of the environment around the fuse is at the margin ofthe range, indicating a fuse that tolerates an increased humidity rangeor a different humidity range is needed. In one more example, themeasured operation data may indicate the usage of the fuse such asinstallation is incorrect by comparing the operational parameters withpredetermined thresholds. In another example, the measured shock may becompared to a threshold shock. In some embodiments, the threshold shockmay be 2 g. A measured shock greater than the threshold may indicatethat the EV 112 traverses a particularly uneven terrain, the EV 112experiences an impact, or the fuse 110 is exposed to a shock thatexceeds the threshold.

In some embodiments, the sensors 120 measure parameters associated withthe fuse 110, and then, the computing device 130 compares the measuredsensor data 132 to one or more threshold values associated with amaximum service life. The maximum service life may be associated with aservice life of the fuse, if the fuse is exposed to conditions which donot exceed the one or more predetermine threshold values. In otherwords, exposure of the fuse 110 to conditions above the predeterminethresholds may result in a decreased service life that is shorter thanthe maximum service life. In some embodiments, the conditions to whichthe fuse 110 is exposed may be compared to similar historical conditionsto which a historical fuse was exposed. If a similar historicalcondition existed, the service life of the historical fuse may be usedto determine a predicted service life of the fuse 110 that is beingmonitored. For example, an historical fuse may have been exposed to aenvironmental condition which exceeded the predetermined threshold foran extended period of time resulting in a decreased and/or shortenedservice life of the historical fuse. The computing device 130 maydetermine that the fuse 110 is also exposed to the same environmentalcondition exceeding the threshold and accordingly the computing device130 may determine that the fuse 110 will also have a similar shortenedlifespan.

In some embodiments, the method 600 includes determining, using thecomputing device 130, one or more metrics based on, at least in part, onthe received sensor data 132. The method 600 may further includecomparing the determined metrics to a predetermined threshold. Forexample, the method 600 may include determining an average temperatureusing temperature data received from the temperature sensor over aperiod of time. The method 600 may include comparing the averagetemperature data to a predetermined average temperature threshold.

The method 600 includes generating 608 a message using the computingdevice 130. The message may include the sensor data 132, one or moredetermined metrics, and/or a warning. The warning is included in themessage when the computing device 130 determined that the sensor data132 exceeded the predetermined threshold. The method 600 includes thecomputing device 130 transmitting 610 the message to the user computingdevice 150. The message may also include instructions that cause atleast a portion of the content of the message to be displayed on theuser interface 152.

In some embodiments, the method 600 includes determining, using thecomputing device 130, one or more of a preventive maintenancerecommendation based on the comparison 606. For example, if the sensordata 132 exceeds the predetermined threshold, preventive maintenance isrecommended to be performed on the fuse 110, e.g., replace fuse. In yetanother example, if the level of voltage is below the predeterminedthreshold, fuse monitoring is continued. In some embodiments, thecomputing device 130 may recommended a fuse type for a replacement fuseor a proper fuse. For example, if the humidity level is above athreshold level, the fuse in use may not tolerate the humidity level andmay prematurely fail. A proper type of fuses that are suited for thehumidity level may be determined and communicated to a user. In someembodiments, the computing device 130 incorporates the preventivemaintenance recommendation into the message transmitted to the usercomputing device 150. The preventative maintenance recommendation mayalso include a warning that indicates the need to control or adjust theconditions to which the fuse 110 is exposed. For example, if the fuse110 has been exposed to a temperature which exceeds the thresholdtemperature the preventative maintenance recommendation may recommendingcooling and/or shutting off the EV 112 until the temperature is belowthe threshold temperature.

In yet another example, the preventative maintenance recommendation maybe associated with fuse inventory management. For example, the computingdevice 130 may determine that the sensor data 132 has crossed one ormore predetermined thresholds, and accordingly, the computing device 130may recommend purchasing one or more new fuses 110 that may be used toreplace the fuse that is being monitored. The computing device 130 maybe communicatively coupled to a fuse inventory database such that thecomputing device 130 may query the inventory database to determine thequantity and types of fuses that are stored.

FIG. 11 is a flowchart of an exemplary method 700 for monitoring thefuse 110. The method 700 includes retrieving 702, by the computingdevice 130, from the historical fuse database 140, a plurality ofhistorical fuse records 142. Each of the historical fuse records 142includes a fuse type, a fuse application, a fuse service life, and/orhistorical fuse data collected by the one or more sensors 120. Thehistorical fuse records 142 may include one more metrics that determinedby the computing device 130, e.g., an average temperature, humidity,and/or pressure.

The method 700 includes the computing device 130 building 704, from theretrieved plurality of historical fuse records 142, a training datasetfor training a model. In some embodiments, the method 700 includesbuilding a fuse specific training datasets which includes a plurality ofhistorical fuse records associated with a specific type of fuse or aspecific type of fuse application. For example, the method 700 mayinclude building 704 a EV training dataset associated with fuses used inEV applications. In yet another example, the method 700 may includebuilding 704 an industrial training dataset associated with fuses usedin industrial applications.

In the exemplary embodiment, the method 700 includes training 706 themodel using the training dataset. The model may be trained using amachine learning algorithm. The model is configured to receive one ormore inputs and determine one or more outputs. The one or more inputsinclude real-time parameters associated with the fuse 110 that is beingmonitored. Real-time parameters may include environmental conditions towhich the fuse 110 is exposed. Real-time parameters may include fuseperformance parameters. The one or more outputs may include a remainingservice life, a remaining number of service life cycles, and/or a fuserecommendation.

In some embodiments, the method 700 does not include retrieving 702,building 704, and training 706. A model that has been trained and/orstored in a separate computing device or in the same computing device isprovided and is used to analyze the sensor data detected by the fusemonitoring assembly 116.

The method 700 includes receiving 708, at the computing device 130, fromone or more sensors 120, sensor data 132. The sensors 120 measure, inreal-time, the environmental conditions to which the fuse 110 isexposed. The sensor may also measure, in real-time, the fuse 110performance parameters. The method 700 includes applying 710 the sensordata 132 as the inputs to the model.

In the exemplary embodiment, the method 700 further includes analyzingthe sensor data 132 using the trained model. The trained model outputsremaining service life, a remaining number of service life cycles, thefunctioning of the fuse, and/or a fuse recommendation based on thesensor data. The functioning of the fuse may include at least one offuse failure or the fuse is still functioning. If the fuse has failed,the output may include a reason, such as, the fuse is blow, the fuse isshort-circuited, the fuse is overload, the fuse has faulted, and/or anincorrect fuse was installed.

In some embodiments, the method 700 includes determining one or moremetrics using the received sensor data 132. The method 700 may includeapplying the determined metrics as inputs to the trained mode andapplying the model includes obtaining the outputs.

The method 700 includes the computing device 130 generating 712 a fusemessage. The fuse message includes outputs obtained from applying 710the model to the inputs. The fuse message may include the predictedremaining service life of the fuse 110. In some embodiments, the messageincludes a recommended fuse type. In some embodiments, the messageincludes sensor data 132, determined metrics. In one embodiment, thefuse message may further include maintenance recommendation generated inmethod 600 of monitoring a fuse. The maintenance recommendation may beupdated or modified based on the predicted life or life cycles of thefuse and/or fuse recommendations. For example, if the predictedremaining life is one month, the fuse message may include arecommendation of checking the inventory of fuses to ensure back-upfuses are available when the fuse fails and/or a recommendation ofincreasing the frequency of physical inspection of the fuse.

In some embodiments, the method 600, 700 further includes generating andproviding an alert to the user computing device 150 or the computingdevice 130 about the performance, the life, and maintenance of the fuse.For example, if the remaining life of the fuse is limited, such as days,an alert may be sent to the user computing device 150 of the computingdevice 130. The alert may be visual, audio, and/or haptic.

The user computing device 150 described herein may be any suitable usercomputing device 800 and software implemented therein. FIG. 12 is ablock diagram of an exemplary computing device 800. In the exemplaryembodiment, the computing device 800 includes a user interface 804(e.g., user interface 152) that receives at least one input from a user.The user interface 804 may include a keyboard 806 that enables the userto input pertinent information. The user interface 804 may also include,for example, a pointing device, a mouse, a stylus, a touch sensitivepanel (e.g., a touch pad and a touch screen), a gyroscope, anaccelerometer, a position detector, and/or an audio input interface(e.g., including a microphone).

Moreover, in the exemplary embodiment, computing device 800 includes apresentation interface 817 (e.g., user interface 152) that presentsinformation, such as input events and/or validation results, to theuser. The presentation interface 817 may also include a display adapter808 that is coupled to at least one display device 810. Morespecifically, in the exemplary embodiment, the display device 810 may bea visual display device, such as a cathode ray tube (CRT), a liquidcrystal display (LCD), a light-emitting diode (LED) display, and/or an“electronic ink” display. Alternatively, the presentation interface 817may include an audio output device (e.g., an audio adapter and/or aspeaker) and/or a printer.

The computing device 800 also includes a processor 814 and a memorydevice 818. The processor 814 is coupled to the user interface 804, thepresentation interface 817, and the memory device 818 via a system bus820. In the exemplary embodiment, the processor 814 communicates withthe user, such as by prompting the user via the presentation interface817 and/or by receiving user inputs via the user interface 804. The term“processor” refers generally to any programmable system includingsystems and microcontrollers, reduced instruction set computers (RISC),complex instruction set computers (CISC), application specificintegrated circuits (ASIC), programmable logic circuits (PLC), and anyother circuit or processor capable of executing the functions describedherein. The above examples are exemplary only, and thus are not intendedto limit in any way the definition and/or meaning of the term“processor.”

In the exemplary embodiment, the memory device 818 includes one or moredevices that enable information, such as executable instructions and/orother data, to be stored and retrieved. Moreover, the memory device 818includes one or more computer readable media, such as, withoutlimitation, dynamic random access memory (DRAM), static random accessmemory (SRAM), a solid state disk, and/or a hard disk. In the exemplaryembodiment, the memory device 818 stores, without limitation,application source code, application object code, configuration data,additional input events, application states, assertion statements,validation results, and/or any other type of data. The computing device800, in the exemplary embodiment, may also include a communicationinterface 830 that is coupled to the processor 814 via the system bus820. Moreover, the communication interface 830 is communicativelycoupled to data acquisition devices.

In the exemplary embodiment, the processor 814 may be programmed byencoding an operation using one or more executable instructions andproviding the executable instructions in the memory device 818. In theexemplary embodiment, the processor 814 is programmed to select aplurality of measurements that are received from data acquisitiondevices.

In operation, a computer executes computer-executable instructionsembodied in one or more computer-executable components stored on one ormore computer-readable media to implement aspects of the inventiondescribed and/or illustrated herein. The order of execution orperformance of the operations in embodiments of the inventionillustrated and described herein is not essential, unless otherwisespecified. That is, the operations may be performed in any order, unlessotherwise specified, and embodiments of the invention may includeadditional or fewer operations than those disclosed herein. For example,it is contemplated that executing or performing a particular operationbefore, contemporaneously with, or after another operation is within thescope of aspects of the invention.

FIG. 13 illustrates an exemplary configuration of a computer device 1001such as the computing device 130 The server computer device 1001 alsoincludes a processor 1005 for executing instructions. Instructions maybe stored in a memory area 1030, for example. The processor 1005 mayinclude one or more processing units (e.g., in a multi-coreconfiguration).

The processor 1005 is operatively coupled to a communication interface1015 such that server computer device 1001 is capable of communicatingwith a remote device such as the processor 118 and/or the one or moresensor 120, or another server computer device 1001. For example,communication interface 1015 may receive data from the processor 118 andthe one or more sensors 120, via the Internet.

The processor 1005 may also be operatively coupled to a storage device1034. The storage device 1034 is any computer-operated hardware suitablefor storing and/or retrieving data, such as, but not limited to,wavelength changes, temperatures, and strain. In some embodiments, thestorage device 1034 is integrated in the server computer device 1001.For example, the server computer device 1001 may include one or morehard disk drives as the storage device 1034. In other embodiments, thestorage device 1034 is external to the server computer device 1001 andmay be accessed by a plurality of server computer devices 1001. Forexample, the storage device 1034 may include multiple storage units suchas hard disks and/or solid state disks in a redundant array ofinexpensive disks (RAID) configuration. The storage device 1034 mayinclude a storage area network (SAN) and/or a network attached storage(NAS) system.

In some embodiments, the processor 1005 is operatively coupled to thestorage device 1034 via a storage interface 1020. The storage interface1020 is any component capable of providing the processor 1005 withaccess to the storage device 1034. The storage interface 1020 mayinclude, for example, an Advanced Technology Attachment (ATA) adapter, aSerial ATA (SATA) adapter, a Small Computer System Interface (SCSI)adapter, a RAID controller, a SAN adapter, a network adapter, and/or anycomponent providing the processor 1005 with access to the storage device1034.

In some embodiments, the processor 1005 includes a user interface 134(shown in FIGS. 1 and 2 ) that receives at least one input from a user.The user interface 134 may include a keyboard that enables the user toinput pertinent information. The user interface 134 may also include,for example, a pointing device, a mouse, a stylus, a touch sensitivepanel (e.g., a touch pad and a touch screen), a gyroscope, anaccelerometer, a position detector, and/or an audio input interface(e.g., including a microphone). The user interface 134 may presentinformation, such as input events and/or validation results, to theuser. The user interface 134 may also include a display adapter that iscoupled to at least one display device. More specifically, in theexemplary embodiment, the display device may be a visual display device,such as a cathode ray tube (CRT), a liquid crystal display (LCD), alight-emitting diode (LED) display, and/or an “electronic ink” display.Alternatively, the presentation interface 817 may include an audiooutput device (e.g., an audio adapter and/or a speaker) and/or aprinter.

The benefits and advantages of the inventive concepts are now believedto have been amply illustrated in relation to the exemplary embodimentsdisclosed.

At least one technical effect of the systems and methods describedherein includes (a) monitoring of fuses operated in an electric vehicle;(b) real-time monitoring of fuses; (c) fuse monitoring using at leastone sensor configured to measure operational paraments and environmentalconditions; (d) predicting life of a fuse based on operational data andenvironmental data associated with the fuse; and (e) providing a userwith preventive or proactive measures to protect electrical powersystems based on the performance and remaining life of the fuse obtainedduring fuse monitoring.

An embodiment of a fuse monitoring system for monitoring a fuse isdisclosed. The system includes a fuse monitoring assembly and a fusemonitoring computing device. The fuse monitoring assembly includes atleast one sensor configured to measure fuse data associated with thefuse, the fuse data including operational data of the fuse andenvironmental data of an environment in which the fuse locates, theenvironmental data including shock and vibrations. The fuse monitoringassembly also includes at least one processor communicatively coupled tothe at least one sensor, the at least one processor configured totransmit the fuse data to a remote computing device. The fuse monitoringcomputing device is positioned remotely from the fuse monitoringassembly, the fuse monitoring computing device including at least oneprocessor in communication with at least one memory device. The fusemonitoring computing device is programmed to receive, from the fusemonitoring assembly, the fuse data, analyze the fuse data, and generatea fuse message based on the analysis.

Optionally, the operational data include a current, a voltage, aresistance, and a temperature of the fuse. The environmental datafurther includes an ambient temperature and humidity of the environment.The fuse monitoring computing device is further programmed to apply afuse model to the fuse data by inputting the fuse data into the fusemodel configured to predict a remaining life of the fuse based on theoperational data and the environmental data, and obtaining an outputfrom the fuse model, the output including the remaining life of thefuse. The fuse monitoring computing device is further programmed togenerate the fuse message including the remaining life. The fusemonitoring computing device is further programmed to apply a trainedfuse model to the fuse data. The fuse monitoring computing device isfurther programmed to retrieve, from a historical fuse database, aplurality of fuse records, each fuse record including at least one ofoperational data or environmental data associated with a historicalfuse, each fuse record further including a life of the historical fuse,generate, from the plurality of fuse records, a training dataset, andtrain the fuse model using the training dataset. The fuse monitoringcomputing device is further programmed to generate the fuse messageincluding a maintenance recommendation based on the analysis. The fusemonitoring computing device is further programmed to compare the fusedata with a plurality of thresholds, and generate the fuse message basedon the comparison. The fuse monitoring computing device is furtherprogrammed to generate the fuse message including a recommendedalternative fuse type. The fuse monitoring computing device is furtherprogrammed to transmit the fuse message to a user computing device. Thefuse monitoring computing device is configured to transmit the fuse datato a remote computing device having a user interface configured todisplay the fuse data. The fuse monitoring assembly and the fusemonitoring computing device are connected as Internet of Things (IoT).The fuse monitoring computing device is further programmed to generatean alert based on the analysis. The fuse monitoring assembly is modular.

An embodiment of a fuse monitoring assembly for monitoring a fuse isdisclosed. The assembly includes at least one sensor and at least oneprocessor. The at least one sensor is configured to measure fuse dataassociated with the fuse, the fuse data including operational data ofthe fuse and environmental data of an environment in which the fuselocates, the environmental data including shock and vibrations. The atleast one processor is communicatively coupled to the at least onesensor, the processor configured to transmit the fuse data to a remotecomputing device.

Optionally, the at least one sensor is further configured to measurecurrent, voltage, resistance, and temperature of the fuse. The at leastone sensor is further configured to measure ambient temperature andhumidity of the environment. The assembly is modular. The fusemonitoring assembly is configured to be installed on a fuse of anelectrical vehicle. The at least one processor is configured to transmitthe fuse data to the remote computing device having a user interfaceconfigured to display the fuse data.

While exemplary embodiments of components, assemblies and systems aredescribed, variations of the components, assemblies and systems arepossible to achieve similar advantages and effects. Specifically, theshape and the geometry of the components and assemblies, and therelative locations of the components in the assembly, may be varied fromthat described and depicted without departing from inventive conceptsdescribed. Also, in certain embodiments, certain components in theassemblies described may be omitted to accommodate particular types offuses or the needs of particular installations, while still providingthe needed performance and functionality of the fuses.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

What is claimed is:
 1. A fuse monitoring system for monitoring a fuse,the system comprising: a fuse monitoring assembly comprising: at leastone sensor configured to measure fuse data associated with the fuse, thefuse data including operational data of the fuse and environmental dataof an environment in which the fuse locates, the environmental dataincluding shock and vibrations; and at least one processorcommunicatively coupled to the at least one sensor, the at least oneprocessor configured to transmit the fuse data to a remote computingdevice; and a fuse monitoring computing device positioned remotely fromthe fuse monitoring assembly, the fuse monitoring computing devicecomprising at least one processor in communication with at least onememory device, the fuse monitoring computing device programmed to:receive, from the fuse monitoring assembly, the fuse data; analyze thefuse data; and generate a fuse message based on the analysis.
 2. Thesystem of claim 1, wherein the operational data include a current, avoltage, a resistance, and a temperature of the fuse.
 3. The system ofclaim 1, wherein the environmental data further includes an ambienttemperature and humidity of the environment.
 4. The system of claim 1,wherein the fuse monitoring computing device is further programmed to:apply a fuse model to the fuse data by: inputting the fuse data into thefuse model configured to predict a remaining life of the fuse based onthe operational data and the environmental data; and obtaining an outputfrom the fuse model, the output including the remaining life of thefuse; and generate the fuse message including the remaining life.
 5. Thesystem of claim 4, wherein the fuse monitoring computing device isfurther programmed to apply a trained fuse model to the fuse data. 6.The system of claim 4, wherein the fuse monitoring computing device isfurther programmed to: retrieve, from a historical fuse database, aplurality of fuse records, each fuse record including at least one ofoperational data or environmental data associated with a historicalfuse, each fuse record further including a life of the historical fuse;generate, from the plurality of fuse records, a training dataset; andtrain the fuse model using the training dataset.
 7. The system of claim1, wherein the fuse monitoring computing device is further programmed togenerate the fuse message including a maintenance recommendation basedon the analysis.
 8. The system of claim 1, wherein the fuse monitoringcomputing device is further programmed to: compare the fuse data with aplurality of thresholds; and generate the fuse message based on thecomparison.
 9. The system of claim 1, wherein the fuse monitoringcomputing device is further programmed to: generate the fuse messageincluding a recommended alternative fuse type.
 10. The system of claim1, wherein the fuse monitoring computing device is further programmed totransmit the fuse message to a user computing device.
 11. The system ofclaim 1, wherein the fuse monitoring computing device is configured totransmit the fuse data to a remote computing device having a userinterface configured to display the fuse data.
 12. The system of claim1, wherein the fuse monitoring assembly and the fuse monitoringcomputing device are connected as Internet of Things (IoT).
 13. Thesystem of claim 1, wherein the fuse monitoring computing device isfurther programmed to: generate an alert based on the analysis.
 14. Thesystem of claim 1, wherein the fuse monitoring assembly is modular. 15.A fuse monitoring assembly for monitoring a fuse, the assemblycomprising: at least one sensor configured to measure fuse dataassociated with the fuse, the fuse data including operational data ofthe fuse and environmental data of an environment in which the fuselocates, the environmental data including shock and vibrations; and atleast one processor communicatively coupled to the at least one sensor,the processor configured to transmit the fuse data to a remote computingdevice.
 16. The assembly of claim 15, wherein the at least one sensor isfurther configured to measure current, voltage, resistance, andtemperature of the fuse.
 17. The assembly of claim 15, wherein the atleast one sensor is further configured to measure ambient temperatureand humidity of the environment.
 18. The assembly of claim 15, whereinthe assembly is modular.
 19. The assembly of claim 18, wherein the fusemonitoring assembly is configured to be installed on a fuse of anelectrical vehicle.
 20. The assembly of claim 15, wherein the at leastone processor is configured to transmit the fuse data to the remotecomputing device having a user interface configured to display the fusedata.